Cleaning tray for electrical components and carrying tool with the same

ABSTRACT

A cleaning tray for electrical components includes a holder having a frame and a pair of crossed inner bars. End portions of the crossed inner bars connect to the frame to separate the frame into four sub-frames. The frame has a bottom bar, two opposite side bars and a top bar which is tilted against the bottom bar for facilitating dropping water. Several male fasteners are formed along inner borders of each of the sub-frames. The cleaning tray is shared by those different electrical components and consequently to reduce tray cost, simplify manufacturing process and increase productive efficiency. The invention also discloses a carrying tool for electrical components with the cleaning tray.

FIELD OF THE INVENTION

The present invention relates generally to a device for fabricating hard disk drives, and more particularly to a cleaning tray for electrical components, such as FPC (flexible printed circuit), AFA (ACA (arm coil assembly) and FPC Assembly), and HSA (head stack assembly) of the hard disk drives, and a carrying tool for the electrical components with the cleaning tray.

BACKGROUND OF THE INVENTION

Disk drives are information storage devices that use thin film magnetic media to store data. A typical disk drive comprises a head stack assembly (HSA) with slider(s) thereon, a magnetic disk mounted on a spindle motor which causes the magnetic disk to spin, and a motor base to enclose the above-mentioned components. The slider(s) flies over the surface of the magnetic disk at a high velocity to read data from or write data to concentric data tracks on the magnetic disk, which is positioned radially by an ACA embedded (e.g. by epoxy potting or overmolding) in a fantail spacer of the HSA. Generally, a voice coil motor (VCM) is used to drive the ACA.

A traditional HSA comprises one or several HGAs, a fantail spacer interposed between the HGAs, and a plurality of securing means to couple the HGAs with the fantail spacer together. A FPC aligns with the fantail spacer by a FPC assembly to electrically connect with the HGAs. The plurality of securing means comprises a bearing, a washer and a nut. In addition, mounting holes are formed in the HGAs, respectively. The fantail spacer also defines a mounting hole. These mounting holes are provided to permit the bearing extend therethrough so as to combine the above-mentioned components together with the help of the washer and the nut.

The HSA is a very precision and critical part in the disk drive, so frequent cleaning and inspection/testing of electrical components of the HSA, such as ACA, FPC, and slider, and the HSA itself are required during the whole AFA/HSA manufacturing process. The manufacturing process of the AFA/HSA will be described hereinafter. For facilitating the description, the assembly of the ACA and the FPC Assembly is designated as AFA hereinafter. The term AFA cleaning means cleaning focus on ACA and FPC prior to assembling the HGAs and the bearing with the AFA. The term HSA cleaning means slider focus cleaning after the bearing and the HGAs have assembled.

As shown in FIG. 1, a traditional AFA/HSA manufacturing process includes the following steps: (111) AFA assembling on metal plate tray in flow line; (112) loading the AFAs onto a cleaning jig; (113) the cleaning jig carrying the AFAs and cleaning the AFAs for the first time; (114) shifting the AFAs from the cleaning jig to a clean flow line tray (the flow line tray should be cleaned before step 114); (115) inspecting/testing the AFAs while carried on the flow line tray; (116) loading the AFAs onto the cleaning jig; (117) the cleaning jig carrying the AFAs and cleaning the AFAs for the second time; (118) shifting the AFAs from the cleaning jig to the clean flow line tray (the flow line tray should be cleaned again before step 118); (119) the flow line tray shipping the AFAs to a next station; (120) assembling each of the AFA with a HGA and a bearing to form a HSA; (121) loading the HSAs onto a HSA injection tray; (122) the HSA injection tray carrying the HSAs and cleaning the HSAs.

As indicated above, the AFA/HSA process needs three kinds of trays, such as metal tray, AFA/HSA flow line tray, and HSA injection tray. The trays used in the prior AFA/HSA process are generally vacuum forming trays which are easily contaminated, such as forming burrs, metal particles and black particles. In order to meet the cleanliness requirement, the trays must be cleaned before the AFA/HSAs are loaded to them. That is, the trays and the AFA/HSAs have to be cleaned separately. Moreover, the AFA/HSA process also needs one or two kinds of cleaning jigs. In one word, the tray and cleaning cost is high.

In addition, in the above-mentioned process, the AFA/HSAs are loaded/unloaded so many times that much no-value stations and operators are needed in the process. Moreover, the AFA/HSAs loaded/unloaded operation causes contamination from directly handle parts.

Hence, a need has arisen for providing a device for fabricating HSA and important components thereof to simplify the AFA/HSA process, avoid contamination, reduce cost, and increase productive efficiency.

SUMMARY OF THE INVENTION

Accordingly, an object of the present invention is to provide a cleaning tray for carrying, cleaning, and shipping electrical components, such as FPC, AFA, and HSA of hard disk drives, during the whole AFA/HSA process, which can be shared by different electrical components.

Another object of the present invention is to provide a carrying tool for electrical components of disk drive devices during fabricating thereof, which can simplify manufacturing process, save several kinds of trays/jigs traditionally used for fabricating the HSA, and thereby improve productive efficiency and reduce cost.

To achieve the above-mentioned objects, the present invention provides a cleaning tray for electrical components comprising: a holder having a frame and a pair of crossed inner bars. End portions of the crossed inner bars connect to the frame to separate the frame into a plurality of sub-frames. The frame has a bottom bar, two opposite side bars and a top bar which is tilted against the bottom bar for facilitating dropping water. A plurality of male fasteners are formed along inner borders of each of the sub-frames.

In an embodiment of the present invention, one of the crossed inner bars is tilted against the bottom bar for facilitating dropping water.

Preferably, the bottom bar is thinner than the top bar for facilitating ultrasonic cleaning.

According to another embodiment of the present invention, the cleaning tray for electrical components further comprises at least one supporter configured for supporting the electrical components thereon. The supporter has a plurality of female fasteners for detachably engaging with the male fasteners of the sub-frames. The male fasteners of the sub-frames each have a raised portion, and the female fasteners of the supporter each have a recessed portion for engaging with the raised portion.

Preferably, the supporter further has a plurality of poles and sockets adapted to hold the electrical components tightly.

A carrying tool for electrical components in accordance with the present invention comprises a plurality of cleaning trays and a pair of covers for respectively covering the two outmost cleaning trays to sandwich the stacked cleaning trays. Each cleaning tray comprises a holder and at least one supporter. The holder has a frame and a pair of crossed inner bars. End portions of the crossed inner bars connect to the frame to separate the frame into a plurality of sub-frames. A plurality of male fasteners are formed along inner borders of each of the sub-frames. The plurality of supporters are configured for supporting the electrical components thereon. Each of the supporters has a plurality of female fasteners for detachably engaging with the male fasteners of the sub-frames. One side of the frame forms at least one protrusion, and an opposite side of the frame defines at least one cutout such that the plurality of cleaning trays are able to be stacked by aligning and engaging the protrusion of one of the cleaning tray with the cutout of another cleaning tray.

According to one embodiment of the present invention, there are two kinds of supporters, one is HSA/AFA supporter, and the other one is FPC supporter. Each holder can be engaged with one HSA/AFA supporter and one FPC supporter, or four FPC supporters, or two HSA/AFA supporters. Therefore, the cleaning tray can be shared by FPC/AFA/HSA.

Preferably, the carrying tool further has a hand-bar for picking up the electrical components to avoid directly handling the electrical components. Therefore, cross contamination of the electrical components is avoided.

In comparison with the prior art, the cleaning tray can replace four kinds of trays/cleaning jigs traditionally used in the AFA/HSA process. For different projects, the holder, the cover, and the hand-bar can be shared, while the supporters can be changed based on the size of any of the FPC/AFA/HSA to be carried. Thus, the tray cost is reduced.

Since the cleaning tray can replace four kinds of trays/cleaning jigs traditionally used in the AFA/HSA process, the load/unload operations of the FPC/AFA/HSA can be reduced, that is, the no-value stations and operators can be reduced. Thereby the productive efficiency is improved, and simultaneity manufacturing cost is reduced.

Since the top bar is tilted against the bottom bar for facilitating dropping water, thereby, the dryness requirement is met.

To summarize, the instant invention meets the cleaning and dryness requirement, avoids contamination, improves productive efficiency, and reduces the cost of fabricating the AFA/HSAs.

Other aspects, features, and advantages of this invention will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of this invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings facilitate an understanding of the various embodiments of this invention. In such drawings:

FIG. 1 is a flowchart of a traditional manufacturing process of a HSA;

FIG. 2 a is a top view of a holder of a cleaning tray in accordance with the present invention;

FIG. 2 b is a cross sectional view of the holder taken along line 2 b-2 b of FIG. 2 a;

FIG. 2 c is a perspective view of the holder shown in FIG. 2 a;

FIG. 2 d is another perspective view of the holder shown in FIG. 2 a;

FIG. 3 a is a perspective view of an HSA/AFA supporter for the cleaning tray;

FIG. 3 b is another perspective view of the HSA/AFA supporter shown in FIG. 3 a;

FIG. 4 a is a perspective view of an FPC supporter for the cleaning tray;

FIG. 4 b is another perspective view of the FPC supporter shown in FIG. 4 a;

FIGS. 5 a-5 b are perspective views of an integrative module of an HSA/AFA supporter and an FPC supporter for the cleaning tray;

FIGS. 5 c-5 d are perspective views of a second integrative module of an HSA/AFA supporter and an FPC supporter for the cleaning tray;

FIG. 5 e is a perspective view of a third integrative module of an HSA/AFA supporter and an FPC supporter for the cleaning tray;

FIG. 5 f is a perspective view of a fourth integrative module of an HSA/AFA supporter and an FPC supporter for the cleaning tray;

FIG. 6 a is a perspective view of an embodiment of the present invention illustrating the holder assembled with one HSA/AFA supporter and one FPC supporter;

FIG. 6 b is a perspective view of an embodiment of the present invention illustrating the holder assembled with two HSA/AFA supporters;

FIG. 6 c is a perspective view of an embodiment of the present invention illustrating the holder assembled with four FPC supporters;

FIG. 7 a is a perspective view of the cleaning tray carrying one AFA, namely, one HSA and one FPC;

FIG. 7 b is a perspective view of the cleaning tray carrying two HSAs;

FIG. 7 c is a perspective view of the cleaning tray carrying four FPCs;

FIG. 8 a is a perspective view illustrating AFA cleaning while carried on the cleaning tray;

FIG. 8 b is a perspective view illustrating HSA cleaning whiled carried on the cleaning tray;

FIG. 9 is a perspective view of a carrying tool for electrical components in accordance with the present invention;

FIG. 10 a is a perspective view of a cover for the carrying tool shown in FIG. 9;

FIG. 10 b is another perspective view of the cover shown in FIG 10 a;

FIG. 11 is a perspective view illustrating the cleaning trays stacked on the cover;

FIG. 12 a is a perspective view of a hand-bar for the carrying tool;

FIG. 12 b is another perspective view of the hand-bar shown in FIG. 12 a; and

FIG. 13 is a flowchart of the method of fabricating a HSA of disk drive devices using the cleaning tray, according to the present invention.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS

Various preferred embodiments of the invention will now be described with reference to the figures. As indicated above, the present invention is directed to a cleaning tray for carrying, cleaning, and shipping electrical components, such as FPC, AFA, and HSA of hard disk drives, during the whole AFA/HSA manufacturing process. The cleaning tray is designed so as to be shared by those different electrical components and consequently to reduce tray cost, simplify manufacturing process and increase productive efficiency. This will be described in great detail hereinafter.

As shown in FIGS. 6 a-6 c, the cleaning tray 2 includes a holder 20 and several supporters 21, 22. The holder 20 can be selectively assembled with one HSA/AFA supporter 21 and one FPC supporter 22, or two HSA/AFA supporters 21, or four FPC supporters 22 respectively shown in FIGS. 6 a-6 c.

Referring to FIGS. 2 a-2 d, according to one preferable embodiment of the present invention, the holder 20 of the cleaning tray 2, made of polycarbonate or polyether imide, has a frame 20 a and a pair of crossed inner bars 205, 206. The frame 20 a has a top bar 201, a bottom bar 202 opposite the top bar 201, and two opposite side bars 203, 204 connecting to end portions of the top bar 201 and the bottom bar 202. End portions of the crossed inner bars 205, 206 connect to the frame 20 a to separate the frame 20 a into a plurality of sub-frames 20 b. In the present embodiment, the crossed inner bars 205, 206 separate the frame 20 a into four sub-frames 20 b. A plurality of male fasteners 207 are formed along inner borders of each of the sub-frames 20 b. The crossed inner bar 206 that connects the two opposite side bars 203, 204 is tilted against the bottom bar 202 for facilitating dropping water. Furthermore, the top bar 201 is also tilted against the bottom bar 202 for facilitating dropping water, and the bottom bar 202 is straight. In addition, one side of the frame 20 a forms four protrusions 209, and an opposite side of the frame 20 a defines four cutouts 208 such that two holders 20 can be stacked by aligning and engaging the protrusions 209 of one of the holders with the cutouts 208 of the other holder.

In another embodiment of the present invention, the bottom bar 202 is thinner than the top bar 201 for facilitating ultrasonic cleaning.

Referring to FIGS. 3 a-3b, FIGS. 4 a-4 b and FIGS. 5 a-5 f, the HSA/AFA supporter 21 and the FPC supporter 22 have several female fasteners 301, 401, 501, 601, 701 respectively for detachably engaging with the male fasteners 207 of the sub-frames 20 b. Therefore, the supporters 21, 22 are able to be selectively assembled with the holder 20 based on the FPC and/or the AFA and/or the HSA to be carried. As shown in FIGS. 3 a-3 b and FIGS. 4 a-4 b, those supporters 21, 22 are designed as separate parts which can be selectively and respectively assembled with the holder 20 based on requirement. As shown in FIGS. 5 a-5 f, those supporters 21, 22 are designed as an integrative module which is integrally formed and can also be assembled with the holder 20 if required. Preferably, the HSA/AFA supporter 21 and the FPC supporter 22 shown in FIGS. 5 e-5 f further have several poles 602, 702 and sockets 603, 703 for holding the HSA/AFA/FPC tightly so that the HSA/AFA/FPC thereon will not fall down when the cleaning tray 2 is turned upside down for inspecting the HSA/AFA/FPC.

In one embodiment of the present invention, the male fasteners 207 of the holder 20 each have a raised portion 207a, and the female fasteners 301, 401 501, 601, 701 of the supporters 21, 22 each have a recessed portion 301 a, 401 a, 501 a, 601 a, 701 a for engaging with the raised portion 207 a.

FIGS. 7 a-7 c illustrate the cleaning tray of the instant invention with objects to be carried, such as HSA, AFA, and FPC. FIG. 7 a shows that one AFA, that is, one HSA 31 and one FPC 32 is held on the HSA/AFA supporter 21 and the FPC supporter 22 separately. FIG. 7b shows that two HSAs 31 are held on the two HSA/AFA supporters 21, and FIG. 7 c shows that four FPCs 32 are held on the four FPC supporters 22.

FIG. 8 a illustrates the state that one AFA 33 is being cleaned while carried on the cleaning tray 2, and FIG. 8b illustrates the state that one HSA 31 is being cleaned while carried on the cleaning tray 2. As shown in FIGS. 8 a-8 b, the cleaning tray 2 with the AFA 33 and the HSA 31 is vertical positioned in the water and then ultrasonic cleaned. Line AA and BB are the water levels of AFA cleaning and HSA cleaning respectively.

As is shown in FIG. 9, a carrying tool for electrical components includes several cleaning trays 2 and a pair of covers 23.

The cover 23 shown in FIGS. 10 a-10 b has four side by side frameworks, each of which is shaped corresponding to the holder 20 of the cleaning tray 2 for fixing the cleaning trays 2 thereon. Referring to FIG. 11 in conjunction with FIG. 9, on each framework of the cover 23, one cleaning tray 2 with FPC and/or AFA and/or HSA carried thereon is placed. Then, other cleaning trays 2 with FPC and/or AFA and/or HSA carried thereon are stacked one another, and then another cover 23 is covered on the last tier of the cleaning trays 2. Finally, the two covers 23 are fastened together by known means to secure the cleaning trays 2 therebetween. In the assembly, the two covers 23 respectively cover the outmost tier of cleaning trays 2 to sandwich the stacked cleaning trays 2 therebetween. In a preferable embodiment, two opposite sides of each cover 23 respectively define a notch 24 for a clip secured therein to fasten the two covers 23. In the embodiment shown in FIG. 9, the two covers 23 fix four stacks of the cleaning trays 2, and each stack of the cleaning trays has 7 cleaning trays, so each carrying tool can carry 28 AFAs or 56 HSAs or 112 FPCs.

In another embodiment of the instant invention, the carrying tool further includes a hand-bar 25 shown in FIGS. 11 a-11 b. The hand-bar 25 is used to clip the electrical components rather than hand directly handling, so cross contamination of electrical components is avoided.

Referring to FIG. 13, the method of fabricating a HSA of a disk drive device using the above-mentioned cleaning tray comprises the steps of: (211) assembling an AFA and loading the AFA onto the cleaning tray; (212) the cleaning tray carrying the AFA and cleaning the AFA for the first time; (213) inspecting and testing the AFA while carried on the cleaning tray; (214) the cleaning tray carrying the AFA and cleaning the AFA for the second time; (215) the cleaning tray shipping the AFA to a next station; (216) assembling the AFA with a HGA and a bearing to form a HSA; and (217) the cleaning tray carrying the HSA and cleaning the HSA.

It can be seen from above detailed description that each holder of the cleaning tray can be engaged with one HSA/AFA supporter and one FPC supporter, or four FPC supporters, or two HSA/AFA supporters. Therefore, the cleaning tray can be shared by FPC/AFA/HSA, and several jigs or tools traditionally used for fabricating the FPC/AFA/HSA are saved.

In comparison with the prior art, the cleaning tray can replace four kind of trays/cleaning jigs traditionally used in the AFA/HSA process. For different projects, the holder, the cover, and the hand-bar can be shared, while the supporters can be changed based on the size of any of the FPC/AFA/HSA to be carried. Thus the tray cost is reduced.

Since the cleaning tray can replace four kinds of trays/cleaning jigs traditionally used in the AFA/HSA process, the load/unload operations of the FPC/AFA/HSA can be reduced, that is, the no-value stations and operators can be reduced. Thereby the productive efficiency is improved, and simultaneity manufacturing cost is reduced. The top bar and one cross bar are tilted against the bottom bar for facilitating dropping water, thereby the dryness requirement is met. Furthermore, since the cleaning tray can be cleaned with the AFA/HSA at the same time, the additional tray cleaning cost is avoided.

The foregoing description of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. Such modifications and variations that may be apparent to those skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims. 

1. A cleaning tray for electrical components comprising: a holder having a frame and a pair of crossed inner bars, end portions of the crossed inner bars connecting to the frame to separate the frame into a plurality of sub-frames; wherein the frame has a bottom bar, two opposite side bars and a top bar which is tilted against the bottom bar for facilitating dropping water, and a plurality of male fasteners are formed along inner borders of each of the sub-frames.
 2. The cleaning tray as claimed in claim 1, wherein one of the crossed inner bars is tilted against the bottom bar for facilitating dropping water.
 3. The cleaning tray as claimed in claim 1, wherein the bottom bar is thinner than the top bar for facilitating ultrasonic cleaning.
 4. The cleaning tray as claimed in claim 1, wherein one side of the frame forms at least one protrusion and an opposite side of the frame defines at least one cutout such that two holders are stacked by aligning and engaging the protrusion of one of the holders with the cutout of the other holder.
 5. The cleaning tray as claimed in claim 1, further comprising at least one supporter configured for supporting the electrical components thereon, the supporter having a plurality of female fasteners for detachably engaging with the male fasteners of the sub-frames.
 6. The cleaning tray as claimed in claim 5, wherein the male fasteners each have a raised portion, and the female fasteners each have a recessed portion for engaging with the raised portion.
 7. The cleaning tray as claimed in claim 5, wherein the supporter further has a plurality of poles and sockets adapted to hold the electrical components tightly.
 8. The cleaning tray as claimed in claim 1, wherein the electrical components are HSA, AFA and/or FPC of disk drive devices.
 9. A carrying tool for electrical components comprising: a plurality of cleaning trays, each cleaning tray comprising a holder and at least one supporter, the holder having a frame and a pair of crossed inner bars, end portions of the crossed inner bars connecting to the frame to separate the frame into a plurality of sub-frames, a plurality of male fasteners being formed along inner borders of each of the sub-frames, the supporters being configured for supporting the electrical components thereon, each of the supporters having a plurality of female fasteners for detachably engaging with the male fasteners of the sub-frames, one side of the frame forming at least one protrusion, and an opposite side of the frame defining at least one cutout such that the plurality of cleaning trays are able to be stacked by aligning and engaging the protrusion of one of the cleaning tray with the cutout of another cleaning tray; and a pair of covers for respectively covering the two outmost cleaning trays thereby sandwiching the stacked cleaning trays.
 10. The carrying tool as claimed in claim 9, further comprising a hand-bar for picking up the electrical components to avoid directly handling the electrical components.
 11. The carrying tool as claimed in claim 9, wherein two opposite sides of each of the cover each define a notch for securing a clip for locking the pair of covers.
 12. The carrying tool as claimed in claim 9, wherein the frame has a bottom bar, two opposite side bars and a top bar which is tilted against the bottom bar for facilitating dropping water.
 13. The carrying tool as claimed in claim 12, wherein one of the crossed inner bars is tilted against the bottom bar for facilitating dropping water.
 14. The carrying tool as claimed in claim 12, wherein the bottom bar is thinner than the top bar for facilitating ultrasonic cleaning.
 15. The carrying tool as claimed in claim 9, wherein the male fasteners each have a raised portion, and the female fasteners each have a recessed portion for engaging with the raised portion.
 16. The carrying tool as claimed in claim 9, wherein the supporter further has a plurality of poles and sockets adapted to hold the electrical components tightly.
 17. The carrying tool as claimed in claim 9, wherein the electrical components are HSA, AFA and/or FPC of disk drive devices. 